Wireless integrated data recorder

ABSTRACT

An integrated data recorder may be positioned within a slot in a tool. The integrated data recorder includes a sensor package that includes one or more drilling dynamics sensors, a processor in data communication with the one or more drilling dynamics sensors, a memory module in data communication with the one or more drilling dynamics sensors, a wireless communications module in data communication with the processor, and an electrical energy source in electrical communication with the memory module, the one or more drilling dynamics sensors, and the processor.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application which claims priorityfrom U.S. provisional application No. 62/859,498, filed Jun. 10, 2019,which is incorporated by reference herein in its entirety.

TECHNICAL FIELD/FIELD OF THE DISCLOSURE

The present disclosure relates generally to oilfield equipment, andspecifically to integrated data recorders for oilfield equipment.

BACKGROUND OF THE DISCLOSURE

Wellbores are traditionally formed by rotating a drill bit positioned atthe end of a bottom hole assembly (BHA). The drill bit may be actuatedby rotating the drill pipe, by use of a mud motor, or a combinationthereof. As used herein, the BHA includes the drill bit. Conventionally,BHAs may contain only a limited number of sensors and have limited dataprocessing capability. The operating life of the drill bit, mud motor,bearing assembly, and other elements of the BHA may depend uponoperational parameters of these elements, and the downhole conditions,including, but not limited to rock type, pressure, temperature,differential pressure across the mud motor, rotational speed, torque,vibration, drilling fluid flow rate, force on the drill bit or theweight-on-bit (“WOB”), inclination, total gravity field, gravitytoolface, revolutions per minute (RPM), radial acceleration, tangentialacceleration, relative rotation speed and the condition of the radialand axial bearings. The combination of the operational parameters of theBHA and downhole conditions are referred to herein as “drillingdynamics.”

To supplement conventional BHA sensors, drilling dynamics data may bemeasured by drilling dynamics sensors. Measurement of these aspects ofelements of the BHA may provide operators with information regardingperformance and may indicate need for maintenance. Conventional downholedrilling dynamics sensors are located on a dedicated sub used to housethe sensors. The conventional downhole drilling dynamics sensor sub ismechanically coupled to a portion of the drill string or the desireddownhole drilling equipment, directly or indirectly. Conventionaldrilling dynamics sensor subs also require physical connections to bemade to retrieve measurements made by the drilling dynamics sensors.

SUMMARY

The present disclosure provides for an integrated data recorderpositioned within a slot in a tool. The integrated data recorder mayinclude a sensor package comprising one or more drilling dynamicssensors. The integrated data recorder may include a processor in datacommunication with the one or more drilling dynamics sensors. Theintegrated data recorder may include a memory module in datacommunication with the one or more drilling dynamics sensors. Theintegrated data recorder may include a wireless communications module indata communication with the processor. The integrated data recorder mayinclude an electrical energy source in electrical communication with thememory module, the one or more drilling dynamics sensors, and theprocessor.

The present disclosure also provides for an integrated data recordersystem. The integrated data recorder system may include an integrateddata recorder. The integrated data recorder may include a sensor packagecomprising one or more drilling dynamics sensors. The integrated datarecorder may include a memory module in data communication with thesensor package. The integrated data recorder may include a wirelesscommunications module in data communication with the processor. Theintegrated data recorder may include a processor in data communicationwith the drilling dynamics sensor. The integrated data recorder mayinclude an electrical energy source in electrical communication with thememory module, the sensor package, and the processor. The integrateddata recorder system may include a tool having a slot. The integrateddata recorder may be positioned within the slot.

The present disclosure also provides for a method. The method mayinclude providing an integrated data recorder positioned within a tool.The integrated data recorder may include a sensor package comprising oneor more drilling dynamics sensors. The integrated data recorder mayinclude a memory module in data communication with the sensor package.The integrated data recorder may include a wireless communicationsmodule in data communication with the processor. The integrated datarecorder may include a processor in data communication with the one ormore drilling dynamics sensors. The integrated data recorder may includean electrical energy source in electrical communication with the memorymodule, the sensor package, and the processor. The method may includetaking measurements using the drilling dynamics sensors. The method mayinclude transmitting the measurements from the drilling dynamics sensorsto an external device using the wireless communications module.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures are not drawn to scale. In fact, the dimensions of the variousfeatures may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 depicts a cross section of an integrated data recorder consistentwith at least one embodiment of the present disclosure.

FIG. 1A depicts the integrated data recorder of FIG. 1 within a toolconsistent with at least one embodiment of the present disclosure.

FIG. 1B is a perspective view of the integrated data recorder of FIG. 1.

FIG. 1C is a partial cross-section of an integrated data recorder andhatch cover consistent with at least one embodiment of the presentdisclosure.

FIG. 2 depicts a cross section of an integrated data recorder consistentwith at least one embodiment of the present disclosure.

FIG. 2A depicts the integrated data recorder of FIG. 2 within a toolconsistent with at least one embodiment of the present disclosure.

FIG. 2B depicts the integrated data recorder of FIG. 2.

FIG. 2C is a side view of a motor mandrel including an integrated datarecorder consistent with at least one embodiment of the presentdisclosure.

FIG. 2D is a side view of a motor mandrel including an integrated datarecorder consistent with at least one embodiment of the presentdisclosure.

FIG. 3 depicts an integrated data recorder within a carrier subconsistent with at least one embodiment of the present disclosure.

FIG. 4 depicts integrated data recorders within a mud motor consistentwith at least one embodiment of the present disclosure.

FIG. 4A depicts a transmission of a mud motor consistent with at leastone embodiment of the present disclosure.

FIG. 5 depicts integrated data recorders within a mud motor consistentwith at least one embodiment of the present disclosure.

FIG. 5A depicts an integrated data recorder consistent with certainembodiments of the present disclosure.

FIG. 5B depicts an integrated data recorder consistent with certainembodiments of the present disclosure

FIG. 6 depicts an integrated data recorder within a friction reductiontool consistent with at least one embodiment of the present disclosure.

FIG. 6A depicts an integrated data recorder within the frictionreduction tool of FIG. 6 consistent with at least one embodiment of thepresent disclosure.

FIG. 7 depicts integrated data recorders within a friction reductiontool and carrier subs consistent with at least one embodiment of thepresent disclosure.

FIGS. 8A-8D depict slots for integrated data recorders within differentportions of a drill bit consistent with embodiments of the presentdisclosure.

FIG. 9 depicts slots for integrated data recorders within a drill bitshank consistent with embodiments of the present disclosure.

FIGS. 10A and 10B depict integrated data recorders in stabilizersconsistent with certain embodiments of the present disclosure.

FIG. 11 depicts a ball seat assembly having an integrated data recorderconsistent with certain embodiments of the present disclosure.

FIG. 12 depicts a stick-slip mitigation tool having an integrated datarecorder consistent with certain embodiments of the present disclosure.

FIG. 13 depicts a turbine having an integrated data recorder consistentwith certain embodiments of the present disclosure.

FIG. 14 is a block diagram of an integrated data recorder consistentwith at least one embodiment of the present disclosure.

FIG. 15 is a block diagram of an integrated data recorder consistentwith at least one embodiment of the present disclosure.

FIG. 16 is a schematic view of a drilling rig including an integrateddata recorder consistent with at least one embodiment of the presentdisclosure positioned in components thereof.

FIG. 16A is a detail cross section view of a connection between a quilland saver sub including a tool joint clamp and integrated data recorderconsistent with at least one embodiment of the present disclosure.

FIG. 17 is a schematic view of a drilling rig including an integrateddata recorder consistent with at least one embodiment of the presentdisclosure positioned in components thereof.

FIG. 18 is a schematic view of a drill string in a wellbore includingintegrated data recorders consistent with at least one embodiment of thepresent disclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof various embodiments. Specific examples of components and arrangementsare described below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to be limiting. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

FIG. 1 depicts an embodiment of integrated data recorder 100 consistentwith at least one embodiment of the present disclosure. The embodimentof integrated data recorder shown in FIG. 1 is a “pressure barrel”design. Integrated data recorder 100 includes sensor package 110. Sensorpackage 110 may include drilling dynamics sensors including, but notlimited to, low-g accelerometers for determination of inclination, totalgravity field, radial acceleration, tangential acceleration, and/orlow-g vibration sensing; and/or gravity toolface; high-g accelerometersfor shock sensing; temperature sensors; three-axis gyroscopes forrotation speed (angular velocity) computation; Hall-effect sensors tomeasure relative rotation speed, along with a magnetic marker ormarkers; one or more strain gauges to measure one or more of tension,compression, torque on bit, weight on bit, bending moment, bendingtoolface, and pressure; and magnetometers for rotation speed (angularvelocity) computation. Sensor package 110 may include any or all ofdrilling dynamics sensors listed and may include other drilling dynamicssensors not listed. Sensor package 110 may include redundant sensors,for example and without limitation, two 3-axis low-g accelerometersand/or two 3-axis gyro sensors. Redundant sensors may improvereliability and accuracy. Further, the drilling dynamics sensors may beused for determination of other drilling dynamics data other than thatlisted. In certain embodiments, one or more of the drilling dynamicssensors may be digital, solid-state sensors. Digital, solid-statesensors may create less noise, have a smaller footprint, have lowermass, be more shock-resistant, be more reliable and have better powermanagement than analog sensors. In some embodiments, one or more of thedrilling dynamics sensors may be analog sensors. In some suchembodiments, analog sensors may be used, for example and withoutlimitation, with analog-to-digital converters. In certain embodiments,the accelerometers may be three-axis accelerometers. The three-axisaccelerometers may be digital or analog sensors, including, but notlimited to quartz accelerometers. In some embodiments, the gyroscopesmay be three-axis gyroscopes.

As used herein, low-g accelerometers may measure up to between +/−16G.As used herein, high-g accelerometers may measure up to between +/−200G.Rotation speed in RPM (revolutions per minute) may be measured, forexample, between 0 and 500 RPM. Temperature may be measured, forexample, between −40° C. and 175° C., between −40° C. and 150° C. orbetween −40° C. and 125° C. As further described herein below, themeasurement range of the sensors may be programmable while integrateddata recorder 100 is within the wellbore. For example, the low-gaccelerometers measurement range may be changed from +/−4G to +/−16Gwhile drilling.

With further attention to FIG. 1, integrated data recorder 100 mayinclude memory module 115 in data communication with sensor package 110.Memory module 115 is adapted to store data gathered by the sensors insensor package 110. Memory module 115 is in data communication withcommunication port 120. Communication port 120 is adapted to provide adata communications link between memory module 115 and a surfaceprocessor. Communication port 120 may be adapted to communicate withother processors in a communication bus (e.g. MWD tool) via a commoncommunication bus, for example, transmitting drilling dynamics data,statistics based on drilling dynamics data, rock mechanics information,or a combination thereof to surface via MWD.

Also depicted in FIG. 1 is processor 105. Processor 105 may be in datacommunication with the sensors in sensor package 110 and memory module115. Processor 105 may control the operation of the sensors in sensorpackage 110, as described herein below. Processor 105 may includeapplication software/firmware stored on a computer readable media, suchas program Flash memory, which is part of Processor 105. Onenon-limiting example of processor 105 with program Flash memory is a16-bit microcontroller, Model SM470R1B1M-HT from Texas Instruments(Dallas, Tex., USA). The application software/firmware may includeinstructions, for example and without limitation, for executingdeep-sleep mode, standby mode, and active mode, as described hereinbelow. The application software/firmware in processor 105 may be loadedand replaced, via communication port bus 176 through communication port120, by a surface processor. Integrated data recorder 100 may furtherinclude a real-time clock, an oscillator, a fuse, and a voltageregulator. Processor 105 includes, but is not limited to amicrocontroller, microprocessor, DSP (digital signal processor), DSPcontroller, DSP processor, FPGA (Field-Programmable Gate Array) orcombinations thereof.

Memory module 115, processor 105, and sensor package 110 and/or thesensors in sensor package 110 may be in electrical communication withelectrical energy source 130. Electrical energy source 130 providespower to processor 105, memory module 115, and the sensors in sensorpackage 110. In some non-limiting embodiments, electrical energy source130 may be a lithium battery. In yet other embodiments, electricalenergy source 130 may be electrically connected to sensors in sensorpackage 110 indirectly through a voltage regulator. In otherembodiments, electrical energy source 130 may be positioned in a packageseparate from sensor package 110. In certain embodiments, electricalenergy source 130 is a battery, such as a rechargeable battery or anon-rechargeable battery. In other embodiments, electrical energy source130 may be a rechargeable or non-rechargeable battery with an energyharvesting device. In some embodiments, the energy harvesting device maybe a piezo-electric energy harvester or a MEMS energy harvester. In someembodiments, the energy harvesting device may include a solenoid coilgenerator with one or more corresponding magnets positioned on acomponent of tool 300.

As depicted in FIG. 1, processor 105, sensor package 110, memory module115, communication port 120, and electrical energy source 130 may behoused within pressure barrel 140. In the embodiment depicted in FIG. 1,pressure barrel 140 is cylindrical or generally cylindrical. In otherembodiments, pressure barrel 140 may be of other shapes adapted tocontain processor 105, sensor package 110, memory module 115,communication port 120, electrical energy source 130, and wirelesscommunications module 122. In some embodiments, the pressure withinpressure barrel 140 is atmospheric or near-atmospheric pressure. In someembodiments, the pressure rating for pressure barrel 140 may be at least15,000 psi.

In some embodiments, the downhole battery life of electrical energysource 130 may be at least 240 hours (or 10 days), and in someembodiments, memory module 115 may have at least 16 M Bytes of storage.In some embodiments, memory module 115 may have up to 8 gigabytes ofstorage.

As further shown in FIG. 1, end caps 125, 135 may be fitted to the endsof pressure barrel 140. In some embodiments, one or more of pressurebarrel 140 or end caps 125, 135 may be formed from a generallyelectrically, magnetically, and/or electromagnetically transparentmaterial. In some embodiments, for example and without limitation,pressure barrel 140 or end caps 125, 135 may be formed from one or moreof a polymer such as polyether ether ketone (PEEK), high-temperaturerubber, high-temperature plastic, or high-temperature ceramic material.Depending on the operating conditions to which integrated data recorder200 will be subjected, a material having high resilience, highmechanical, chemical, and temperature resistance may be used. Forexample, integrated data recorder 200 used in an oil or gas wellbore mayencounter higher temperatures, pressures, and chemical reactivity thanintegrated data recorder 200 used in a mining operation, and may,accordingly, be built of more resilient materials.

In certain embodiments, communication port 120 may protrude throughmemory dump end cap 125.

FIG. 1A depicts integrated data recorder 100 within tool 300 in oneembodiment of the present disclosure. In some embodiments, tool 300 maybe any component of a drill or tool string within a wellbore, and mayinclude, for example and without limitation, a component of a BHA, drillbit, stabilizer, cross-over, drill pipe, drill collar, pin-boxconnection, jar, reamer, underreamer, friction reducing tool, stringstabilizer, near-bit stabilizer, mud motor, turbine, stick-slipmitigation tool, or bearing housing. In some embodiments, tool 300 maybe any steerable tool, including, for example and without limitation, astraight motor, a steerable motor, a steerable wired-motor, steerableturbine, steerable wired-turbine, steerable gear-reduced turbine,motor-assisted rotary-steerable tool, turbine-assisted rotary-steerabletool, gear-reduced turbine-assisted rotary-steerable tool, MWD(measurement-while-drilling) integrated steerable tool, or coiled tubingsteerable tool. In some embodiments, tool 300 may be part of an oil andgas drilling string or may be part of a mining tool or mining stringincluding a mining bit. In some embodiments, tool 300 may be a componentof a drill or tool string located at the surface for drilling,geothermal drilling, coring and mining or may be a piece of equipmentcoupled to the drill string and may include, for example and withoutlimitation, a Kelly shaft, saver sub, tool joint connection clamp, orcomponent of a top drive such as a quill.

As shown in FIG. 1A, integrated data recorder may be placed behind hatchcover 310 in slot 315 in tool 300. Slot 315 may be machined or drilled,for example, into outside surface 330 of tool 300. FIG. 1B depicts therelative size of integrated data recorder 100 consistent with certainembodiments of the present disclosure. The size of integrated datarecorder 100 depicted in FIG. 1B is not limiting and may be of any sizeconsistent with usage in tool 300. In some embodiments, as depicted inFIG. 1C, integrated data recorder 100 may include location pin 145.Location pin 145 may engage with locator slot 145′ of hatch cover 310.In some embodiments, location pin 145 may not be used. In someembodiments, hatch cover 310 may be at least partially formed from anelectrically, magnetically, and/or electromagnetically transparentmaterial.

FIG. 2 depicts integrated data recorder 200 consistent with certainembodiments of the present disclosure. The embodiment of integrated datarecorder 200 shown in FIG. 2 is a “hockey-puck” design. Integrated datarecorder 200 includes communication port 120, wireless communicationsmodule 122, and electrical energy source 130. Integrated data recorder200 also includes data/sensor module 150. Data/sensor module 150 mayinclude a processor, sensor package containing sensors, and memorymodule, as those elements are described above with respect to integrateddata recorder 100. Data/sensor module 150 may be in data communicationwith communication port 120.

The hockey-puck design of integrated data recorder 200 depicted in FIG.2 may include disk 155. In some embodiments, disk 155 may includerecorder cap 160 and recorder carrier 165. In some embodiments, disk 155may include recorder cap 160 without recorder carrier 165. In someembodiments, one or both of recorder cap 160 and recorder carrier 165may be formed from a generally electrically, magnetically, and/orelectromagnetically transparent material. In some embodiments, forexample and without limitation, recorder cap 160 or recorder carrier 165may be formed from one or more of a polymer such as polyether etherketone (PEEK), high-temperature rubber, high-temperature plastic, orhigh-temperature ceramic material. Depending on the operating conditionsto which integrated data recorder 200 will be subjected, a materialhaving high resilience, high mechanical, chemical, and temperatureresistance may be used. For example, integrated data recorder 200 usedin an oil or gas wellbore may encounter higher temperatures, pressures,and chemical reactivity than integrated data recorder 200 used in adrilling, geothermal drilling, coring, or mining operation, and may,accordingly, be built of more resilient materials. In certainembodiments, communication port 120 may be positioned within disk 155,accessible by removing recorder cap 160 from recorder carrier 165. Insome embodiments, integrated data recorder 200 may include location pin215 formed as part of or mechanically coupled to recorder carrier 165.In some embodiments, location pin 215 may not be used. In someembodiments, communication port 120 may be positioned proximate to orwithin location pin 215.

Integrated data recorder 200 may be positioned within any tool 300 asdescribed herein above with respect to integrated data recorder 100. Asa non-limiting example of an embodiment of the present disclosure, FIG.2A depicts integrated data recorder 200 within bit sub 302 of, forexample and without limitation, a motor mandrel. As depicted in FIGS.2C, 2D, bit sub 302 may be mechanically coupled to motor mandrel 305.Motor mandrel 305 may include pin-down lower coupler 307 a as depictedin FIG. 2C, or may include box-down lower coupler 307 b as depicted inFIG. 2D. In certain embodiments, integrated data recorder 200 may bepositioned within screw housing 230. Screw housing may include screwhousing threads for threadedly connecting to threaded slot 240, as shownin FIG. 2A. The hockey-puck design of integrated data recorder 200 maybe used, for example and without limitation, in areas with limited spacesuch as a motor mandrel bit box, a steerable tool bit box, a verticaldrilling tool bit box, a steerable tool upper mandrel, a verticaldrilling tool upper mandrel, stabilizer, ball seat, a shank of a drillbit, a kelly, a saver sub, a tool joint connection clamp, or a quill ofa top drive. In some embodiments, integrated data recorder 100 or 200may be used in any of these tools.

FIG. 2B depicts the relative size of integrated data recorder 200consistent with certain embodiments of the present disclosure. The sizeof integrated data recorder 200 depicted in FIG. 2B is not limiting andmay be of any size consistent with usage in tool 300.

In certain embodiments, integrated data recorder 100 and integrated datarecorder 200 may be self-contained in that while recording data, nopower is supplied from outside integrated data recorder 100 orintegrated data recorder 200, respectively. In other embodiments,electrical power may be supplied from outside integrated data recorder100 and 200, such as from a self-contained, separate electrical powermodule such as, for example, batteries.

FIG. 14 depicts a block diagram of integrated data recorder 100, 200.Integrated data recorder includes sensor package 110 which includes oneor more sensors. In the embodiment shown in FIG. 14, the sensors mayinclude one or more of low-g accelerometer 111, high-g accelerometer112, gyroscope 113, and temperature sensor 114. In some embodiments,such as the embodiment shown in FIG. 14, the sensors may also includeone or more of magnetometer 116, pressure sensor 117, and strain gauge119. In other embodiments, sensor package 110 may include any of sensors111, 112, 113, 114, 116, 117, and 119. Sensors 111, 112, 113, 114, 116,117, and 119 may be in data communication with processor 105 throughsensor communication bus 170. Sensor communication bus 170 may be adigital communication bus, such as an SPI (Serial Peripheral Interface)bus or an I²C (Inter-Integrated Circuit) bus.

In certain embodiments, Hall-effect sensor 118 may be in datacommunication with processor 105 through Hall-effect sensor bus 172.Hall-effect sensor bus 172 may be a digital communication bus, such asan SPI or an I²C bus. In some embodiments, Hall-effect sensor 118 isdirectly connected to processor 105 via an input port, for example, aninterrupt pin or an analog-to-digital-converter pin. In otherembodiments, Hall-effect sensor 118 may be a digital Hall-effect sensoror analog (ratio-metric) Hall-effect sensor. In other embodiments,Hall-effect sensor 118 may be omitted.

In the embodiment depicted in FIG. 14, memory module 115 is in datacommunication with processor 105 through memory communication bus 174.Memory communication bus 174 may be a CAN (Controller Area Network) bus,an SPI or an I²C bus in certain non-limiting examples. Thus, sensors111, 112, 113, 114, 116, 117, and 119 are in data communication withmemory module 115 through sensor communication bus 170, processor 105,and memory communication bus 174. Hall-effect sensor 118 is in datacommunication with memory module 115 through Hall-effect sensor bus 172,processor 105 and memory communication bus 174. Memory module 115 maycontain multiple memory devices, such as between 2 and 8 memory devicesor 4 memory devices. Each memory device may be a non-volatile memorymedium, such as Flash or EEPROM (Electrically Erasable ProgrammableRead-Only Memory) device. One non-limiting example of EEPROM device is a1-kbit SPI EEPROM, Model 25LC010A from Microchip (Chandler, Ariz., USA).

As further shown in FIG. 14, processor 105 is in data communication withcommunication port 120 through communication port bus 176. Communicationport bus 176 may be a digital communication bus, including, but notlimited to, a SCI (Serial Communication Interface) bus, a UART(Universal Asynchronous Receiver/Transmitter) bus, a CAN bus, a SPI busor a I²C bus. Communication port 120 may be in data communication withmemory module 115 through memory communication bus 174, processor 105,and communication port bus 176. One non-limiting example of processor105 with such communication bus feature is a 16-bit microcontroller,Model SM470R1B1M-HT from Texas Instruments (Dallas, Tex., USA).

In some embodiments, as further shown in FIG. 14, processor 105 may bein data communication with wireless communications module 122 throughwireless communication bus 177. Wireless communication bus 177 may be adigital communication bus, including, but not limited to, a SCI (SerialCommunication Interface) bus, a UART (Universal AsynchronousReceiver/Transmitter) bus, a CAN bus, a SPI bus or a I²C bus. Wirelesscommunications module 122 may be in data communication with memorymodule 115 through memory communication bus 174, processor 105, andwireless communication port bus 177. Wireless communications module 122may, in some embodiments, allow for wireless communication betweenintegrated data recorder 100 or integrated data recorder 200 andexternal device 180 as further discussed below. External device 180 maybe, for example and without limitation, one or more of a computer,mobile device, personal computer, tablet, smartphone, external datalogger, or other suitable system. Wireless communications module 122may, for example and without limitation, allow for data from memorymodule 115 to be transmitted to external device 180 without physicallyinteracting with integrated data recorder 100 or integrated datarecorder 200. In some embodiments, external device 180 may upload orstream data from integrated data recorder 100, 200 to a remote locationsuch as, for example and without limitation, a server or cloud network.In some embodiments, integrated data recorder 100 or integrated datarecorder 200 may remain installed to tool 300 while data is retrievedfrom memory module 115. In some embodiments, wireless communicationsmodule 122 may, for example and without limitation, allow fordata/commands from external device 180 to be received by processor 105without physically interacting with integrated data recorder 100 orintegrated data recorder 200. In some embodiments, the operationalsetting of integrated data recorder 100 or integrated data recorder 200may be changed wirelessly. In some embodiments, external device 180 maybe surface equipment with Internet connection or a downhole tool withina drillstring.

Wireless communications module 122 may use any wireless communicationprotocol for communicating between integrated data recorder 100, 200 andexternal device 180 including, for example and without limitation, oneor more of WiFi, Bluetooth, Bluetooth low energy (BLE), ZigBee, Z-Wave,GSM (Global System for Mobile Communications), CDMA (Code-divisionmultiple access), UMTS (Universal Mobile Telecommunications System), LTE(Long-Term Evolution), GPS (Global Positioning System), satellitecommunication, or any other wireless communication protocol.

In some embodiments, wireless communications module 122 may be atransceiver such that data or commands transmitted from external device180 may be received by integrated data recorder 100 or integrated datarecorder 200. In some such embodiments, external device 180 may sendinstructions to integrated data recorder 100 or integrated data recorder200 to, for example and without limitation, configure one or moreparameters of sensor package 110 or configure an operational mode ofintegrated data recorder 100 or integrated data recorder 200. In someembodiments, for example and without limitation, synchronization orcalibration of sensors or other parameters of integrated data recorder100 or integrated data recorder 200 may be accomplished using commandstransmitted wirelessly from external device 180 to wirelesscommunications module 122.

FIG. 15 depicts another embodiment of a block diagram of integrated datarecorder 100, 200. In FIG. 15, sensor communication bus 170 and memorycommunication bus 174 are connected to form sensor-memory bus 175.

In the embodiments shown in FIGS. 14 and 15, electrical energy source130 is in electrical connection with each of sensors 111, 112, 113, 114,116, 117, 119, processor 105, memory module 115, and wirelesscommunications module 122. In some embodiments, electrical energy source130 may be electrically connected to each of sensors 111, 112, 113, 114,116, 117, 119 directly. In other embodiments, electrical energy source130 may be electrically connected to each of sensors 111, 112, 113, 114,116, 117, 119 indirectly through a connection to sensor package 110. Inyet other embodiments, electrical energy source 130 may be electricallyconnected to each of sensors 111, 112, 113, 114, 116, 117, 119indirectly through a voltage regulator.

In some embodiments, communication port 120 may include a power bus usedto provide power to recharge electrical energy source 130. In someembodiments, integrated data recorder 100, 200 may include one or morewireless charging apparatuses to, for example and without limitation,allow electrical energy source 130 to be charged without dismantlingintegrated data recorder 100, 200.

In some embodiments, tool 300 into which integrated data recorder 100 orintegrated data recorder 200 is integrated may be a downhole tool usedas part of a drill or tool string positioned within a wellbore. As anonlimiting example, FIG. 3 depicts integrated data recorder 100 withincarrier sub 320 consistent with at least one embodiment of the presentdisclosure. In other embodiments, integrated data recorder 200 may bepositioned within carrier sub 320. Carrier sub 320 may be inserted intoa drill string, for examples and without limitation, between two jointsof a drill string. In some embodiments, carrier sub 320 may be a bitsub. In some embodiments, carrier sub 320 may include male threadedconnection 322 and female threaded connection 324 for threaded insertioninto the drill string. Although not depicted, in other embodiments,carrier sub 320 may include two female threaded connections or two malethreaded connections.

Integrated data recorder 100, 200 may be used with a variety of tools ofwhich bit sub 302 is a part. In one non-limiting example, integrateddata recorder 100 may be used with mud motor 400, as shown in FIG. 4.Mud motor 400 may include rotor catch 410 within a top sub, transmission430 and bit box 450. As shown in FIG. 4, rotor catch recorder 425 may bepositioned within rotor catch slot 420, located, for instance, proximaterotor catch 410, and bit box recorder 465 may be positioned in bit boxslot 460, located proximate bit box 450. In certain embodiments, such asshown in FIG. 4, transmission recorder 445 may be positioned withintransmission slot 440 located proximate transmission 430. Althoughdepicted at an upper end of transmission 430, transmission slot 440 andtransmission recorder 445 may be positioned at any position withintransmission 430, including, for example and without limitation, at alower end of transmission 430 as depicted in FIG. 4A. Rotor catchrecorder 425, bit box recorder 465 and transmission recorder 445 mayinclude sensors for measuring lateral and axial shock and vibration,string and drill bit RPM, toolface, inclination, total gravity field,temperature, radial acceleration, tangential acceleration, andcombinations thereof, for example.

FIG. 5 depicts another embodiment of the use of integrated data recorder100, 200 in conjunction with mud motor 400 (shown in FIGS. 5A and 5B,respectively). In the embodiment depicted in FIG. 5, integrated datarecorder 100 may be used for top sub recorder 485, positioned in top sub480 and integrated data recorder 200 may be used for bit box recorder465, positioned in bit box threaded slot 462.

In another embodiment, integrated data recorder 100, 200 may be used inconjunction with a friction reduction tool. Non-limiting examples offriction reduction tools may be found in U.S. Pat. No. 6,585,043entitled “Friction Reducing Tool” and U.S. Pat. No. 7,025,136 entitled“Torque Reduction Tool,” which are incorporated herein by reference.FIG. 6 depicts one embodiment of the use of integrated data recorder 100in friction reduction tool 500. Friction reduction tool 500 may includeamplifier section 510 in mechanical connection with pulser section 520.Pulser section may include valve section 540 in mechanical and fluidand/or electrical connection with power section 530. In the embodimentshown in FIGS. 6 and 6A, integrated data recorder 100 may be positionedin friction reduction recorder slot 535. Sensors within frictionreduction recorder data dynamics recorder may be used to determine thefrequency and intensity of operation of friction reduction tool 500.Friction reduction recorder slot 535 may be located within pulsersection 520 or amplifier section 510. As shown in FIG. 6, frictionreduction recorder slot 535 is positioned within amplifier section 510.

Integrated data recorder 100, 200 within carrier sub 320 may be used inconjunction with a variety of tool subcomponents that make up tool 300.In one non-limiting example, integrated data recorder 100 may be usedwith a friction reduction tool, as shown in FIG. 6 and a mud motor, asshown in FIG. 5. As discussed above with respect to mud motor 400, oneor more of rotor catch recorder 425, top sub recorder 485, and bit boxrecorder 465 may be positioned in mud motor 400. Friction reductionrecorder slot 535 may be positioned within friction reduction tool 500.As shown in FIG. 7, friction reduction tool 500 and mud motor 400 may bemechanically coupled by intermediate drill string section 710.Intermediate carrier sub 550 containing integrated data recorder 100 maybe positioned within intermediate drill string section 710. In certainembodiments, as shown in FIG. 7, upper carrier sub 545 may be positionedwithin upper drill string section 720. The sensors within integrateddata recorders 100 within upper carrier sub 545 and intermediate carriersub 550 may be used to gather data to evaluate transmission ofoscillation through bit box 450 and the drill string.

In another embodiment, integrated data recorder 100, 200 may bepositioned within a drill bit. In some embodiments, the sensors withinintegrated data recorder 100, 200 may be used to determine bit dynamicsand the operating condition of the bit. FIGS. 8A-8D depict locations inwhich integrated data recorders 100 may be positioned within drill bit800. FIG. 8A depicts shank slot 810. FIG. 8B depicts blade shoulderthreaded slot 820. FIG. 8C blade threaded slot 830. FIG. 8D depicts bodythreaded slot 840. Although depicted as a drilling bit, drill bit 800may be any type of drill bit for use in forming a bore including, forexample and without limitation, a roller cone bit, PDC bit, coring bit,geothermal drilling bit, or mining bit as understood in the art.

FIG. 9 depicts slots for use with integrated data recorder 100, 200within drill bit shank 455. In the example shown in FIG. 9, slot 910 andthreaded slot 920 are shown for use with integrated data recorder 100,200, respectively.

FIGS. 10A and 10B depict integrated data recorder 200 in near-bitstabilizer 1000 and stabilizer 1050, respectively for use in, forexample, a coring or drilling assembly. FIG. 10A depicts integrated datarecorder 200 positioned in blade 1060 of stabilizer body 1010. In someembodiments, integrated data recorder 200 may be positioned in betweenadjacent blades 1060 in stabilizer body 1010. FIG. 10B depictsintegrated data recorder 200 positioned in blade 1060.

FIG. 11 depicts ball seat assembly 1100 for use, for example, with acoring assembly. Ball seat assembly 1100 includes inner bore 1110 inwhich ball seat 1120 is positioned. In the embodiment shown in FIG. 11,integrated data recorder 100, 200 may be positioned within ball seatslot 1130 formed within ball seat outer wall 1140 proximate ball seat1120. In certain embodiments, integrated data recorder 100, 200 may bepositioned within near-bit stabilizer 1000, 1050 as discussed hereinabove, and another integrated data recorder 100, 200 positioned withinball seat assembly 1100. The integrated data recorder 100, 200 withinnear-bit stabilizer 1000, 1050 may measure shock, vibration, rotationspeed (in RPM), inclination, toolface, total gravity field, radialacceleration, tangential acceleration or a combination thereof, forexample. Sensor measurements taken by sensors within near-bit stabilizer1000, 1050 in combination with sensor measurements taken by sensorswithin ball seat assembly 1100 may determine drilling dynamicsthroughout the coring assembly. In some embodiments, outer wall 1140 maybe formed at least partially from an electrically, magnetically, and/orelectromagnetically transparent material aligned with integrated datarecorder 100, 200

FIG. 12 depicts integrated data recorder 100, 200 positioned withinstick-slip mitigation tool 1200 in stick-slip tool slot 1210. Stick-slipmitigation tool 1200 may also be referred to as a constant weight-on-bittool. FIG. 13 depicts integrated data recorder 100, 200 positionedwithin turbine 1300 in turbine slot 1310. In some embodiments,integrated data recorder 100, 200 may be positioned within rotor 1315,stator 1320, or output shaft 1325 of turbine 1300.

In some embodiments, tool 300 into which integrated data recorder 100 orintegrated data recorder 200 is integrated may be a surface tool used aspart of a drill or tool string or may be coupled to a piece of equipmentused with the drill string. As a nonlimiting example, FIG. 16 depictsdrilling rig 600, which may be a drilling rig, geothermal drilling rig,coring rig, or mining rig. Drilling rig 600 may include rig floor 601,substructure 603, and mast 605. In some embodiments, drilling rig 600may include top drive 607. Top drive 607 may include quill 609. Quill609 may couple to the top of the drill string, depicted as drill string611, and may be used to rotate drill string 611 during a drillingoperation. Top drive 607 may also be used to move drill string 611vertically within the wellbore. In some embodiments, quill 609 maycouple directly to drill string 611 or may, as depicted in FIG. 16,couple to drill string 611 through saver sub 613. In some embodiments,one or more integrated data recorders 100, 200 may be positioned withinone or more components of drilling rig 600 including, for example andwithout limitation, quill 609 of top drive 607 or within saver sub 613.In some embodiments, integrated data recorder 100 may be at a constantcommunication with external device 180, which may be a surface device.

In some embodiments, as shown in FIG. 16A, tool joint clamp 614 may beused at the connection between quill 609 and saver sub 613. Tool jointclamp 614 may, for example and without limitation, reduce the likelihoodthat saver sub 613 is unintentionally unthreaded from quill 609. In someembodiments, tool joint clamp 614 may include slot 616 into whichintegrated data recorder 100, 200 may be positioned.

In some embodiments, drilling rig 600 may include kelly 615 as depictedin FIG. 17. Kelly 615 may be coupled to the upper end of drill string611 and may be used to rotate drill string 611 using rotary table 617.In some embodiments, integrated data recorder 100, 200 may be positionedwithin kelly 615 or within saver sub 613 positioned between kelly 615and drill string 611.

In some embodiments, multiple integrated data recorders 100, 200 may beincluded within a single drill string or tool string coupled to varioustools 300 at various locations throughout the drill string or toolstring. In some such embodiments, as depicted in FIG. 18, integrateddata recorders 100, 200 may be located within both downhole and surfacetools of the drill string or tool string. For example, integrated datarecorders 100, 200 may be positioned in BHA near drill bit 800 or in bitbox 450 and positioned spaced apart from drill bit 800 such as at topsub 480. Additionally, one or more integrated data recorders 100, 200may be positioned at a component of drilling rig 600 such as, forexample and without limitation, quill 609 of top drive 607, saver sub613, or Kelly 615. In some embodiments, measurements may be taken withall integrated data recorders 100, 200 as discussed further below.

In operation, the sensors in sensor package 110 of one or moreintegrated data recorders 100, 200 located in a downhole tool 300located within the wellbore may measure drilling dynamics data. Thedrilling dynamics data may be stored in memory module 115, referred toherein as “memory logging,” during the drilling process. When tool 300is retrieved from the wellbore and positioned at the surface, drillingdynamics data may be retrieved from memory module 115 through wirelesscommunications module 122 without removing integrated data recorders100, 200 from the downhole tool 300 and may be used by a surfaceprocessor such as external device 180. For example, in some embodiments,such as during a drilling, geothermal drilling, or mining operation,tool 300 may be retrieved from the wellbore, drilling dynamics data maybe retrieved wirelessly from integrated data recorder 100 or 200, andtool 300 may be redeployed without any disassembly of tool 300 orwithout physically connecting to integrated data recorder 100 or 200.

In some embodiments, external device 180 at the surface may include asurface processor connected to a cloud data storage and computingserver. In some such embodiments, the wirelessly retrieved data may bestored in the cloud data storage and may be processed in the cloudserver. For example and without limitation, in some embodiments, a runsummary, including rotating hours, flow-on hours, vibration-on hours,shock statistics, stick-slip statistics, or other data gleaned fromintegrated data recorders 100, 200 may be generated in the cloud serverand sent to one or more client devices via the Internet. In someembodiments, both surface recorded drilling dynamics data and downholerecorded drilling dynamics data may be quality-controlled (QC′ ed), inthe cloud computing system, and combined with data from a surfaceElectronic Drilling Recorder (EDR). In some embodiments, a drillingdynamics log and accelerometer/gyro spectrograms, such as in JPEG (JointPhotographic Experts Group), PDF (Portable Document Format), may begenerated in the cloud computing system. In some embodiments, one ormore pattern recognition algorithms (e.g. based on artificialintelligence and machine learning) may be run on the combined data setsto identify, for example and without limitation, operational anomaliesand/or data anomalies.

In some embodiments, the sensors in sensor package 110 of one or moreintegrated data recorders 100, 200 located at the surface maycontinuously or continually transmit drilling dynamics data recordedfrom the piece of surface equipment such as top drive 607, quill 609,saver sub 613, or kelly 615 through wireless communications module 122for use by the surface processor such as external device 180.

In some embodiments, the surface processor may use the drilling dynamicsdata for post-run and/or continuous (in the case of surface toolsincluding integrated data recorders 100, 200) evaluation of drillingdynamics, frequency spectrum, statistical analysis, and Condition BasedMonitoring/Maintenance (CBM). In some embodiments, frequency spectrumanalysis may be done, for example, by applying discrete Fouriertransform (or fast Fourier transform) to burst data. In someembodiments, statistical analysis may be done, for example, calculatingminimum, maximum, median, mean, mode, root-mean-squared values, standarddeviation, and variance of burst data. Statistical analysis may includemaking histograms of, for example, temperature, vibration, shock,inclination, rotation speed, rotation speed standard deviation, andvibration/shock standard deviation. Temperature histograms may include,for example, accumulating the data points in certain temperature binsover multiple deployments (runs) of the sensors and downhole tools.

CBM is maintenance performed when a need for maintenance arises. Thismaintenance is performed after one or more indicators show thatequipment is likely to fail or when equipment performance deteriorates.CBM may apply systems that incorporate active redundancy and faultreporting. CBM may also be applied to systems that lack redundancy andfault reporting.

CBM may be designed to maintain the correct equipment at the right time.CBM may be based on using real-time data, recorded data, or acombination of real-time and recorded data to prioritize and optimizemaintenance resources. Observing the state of a system is known ascondition monitoring. Such a system will determine the equipment'shealth, and act when maintenance is necessary. Ideally, CBM will allowthe maintenance personnel to do only the right things, minimizing spareparts cost, system downtime and time spent on maintenance.

Drilling dynamics data, such as high-frequency continuously sampled andrecorded data, wherein high-frequency data refers to data at 800 Hz-3200Hz, may be used for rock mechanics analysis. Such rock mechanicsanalysis include the analysis/identification of fractures, fracturedirections, rock confined/unconfined compressive strength, Young'smodulus of elasticity, shear modulus, and Poisson's ratio. Such rockmechanics analysis may be accomplished by combining with surfacemeasured parameters, such as WOB (weight on bit), TOB (torque on bit),RPM (revolutions per minute), ROP (rate of penetration), and flow rate.Pseudo formation-evaluation log, such as pseudo-sonic log,pseudo-neutron log, pseudo-porosity log, pseudo-density log,pseudo-Gamma log may be generated with a combination of the analysis ofhigh-frequency continuously sampled and recorded data, along withsurface parameters, and other formation-evaluation data, such as naturalGamma log and other logging-while-drilling (LWD) logs. Alternatively,high-frequency continuously-sampled data (e.g. at 800 Hz-3200 Hz) may beused for real-time rock mechanics analysis. Rock mechanical parametersmay also be referred to as geomechanical parameters. Alternatively,pseudo-formation evaluation log, such as pseudo-Gamma log may begenerated downhole and transmitted to the surface for real-timegeo-steering.

In some embodiments, the sensors in sensor package 110 of each of theone or more integrated data recorders 100, 200 located both at thesurface and downhole may be identical. In some embodiments, integrateddata recorders 100, 200 located both at the surface and downhole may beoperated such that all integrated data recorders 100, 200 record thesame data at the same or higher resolution. In such an embodiment, thesurface processor may receive and analyze drilling dynamics data fromboth surface and downhole integrated data recorders 100, 200, gatheredby identical sensor packages 110 in both the surface and downholeintegrated data recorders 100, 200. For example, the surface processormay compare surface drilling dynamics data with downhole drillingdynamics data to identify operational anomalies and earlier detection ofdownhole dysfunctions. As a non-limiting example, data from downholesensors connected to a MWD wirelessly or with a physical connection maybe transmitted to the surface. However, the transmission speed of thereal-time data via, for example, mud pulse telemetry may be very low,such as at 1-2 bits per second. By correlating the downhole and surfacedrilling dynamics data recorded by integrated data recorders 100, 200,some correlation of, for example, bit drilling dynamics and surfacedynamics data, could be identified. Using this correlation to detectearly signs of one or more downhole problems, the surface data can beused to monitor downhole problems and operational anomalies. The surfacesensor data may be transmitted to the surface computer at the wirelesscommunication speed, such as at 1-10 gigabits per second in real time.The surface data received at the surface computer may be moved to acloud computing system via the internet for further real-time and/ornon-real-time processing. Due to the limitations to transmission of datafrom downhole to the surface, the use of surface drilling dynamics data(in conjunction with the downhole data correlation) may allow for betterand more economical determinations of downhole problems or operationalanomalies. In other embodiments, surface and downhole integrated datarecorders 100, 200 may be operated in different modes. In someembodiments, when an anomaly is detected from the surface drillingdynamics data, a rig automated control system may adjust surfaceparameters until a different or smoother signal is received.

Power from electrical energy source 130 may be supplied to the sensorsin sensor package 110. In some embodiments, the electrical power fromelectrical energy source 130 to the sensors in sensor package 110 isalways on (powered up) but at different levels. At the lowest powerlevel, which in some embodiments may be used while integrated datarecorder 100, 200 are being transported, integrated data recorder 100,200 may be in “deep-sleep mode.” In deep sleep mode, the real-timeclock, sensors, for example, sensors 111, 112, 113, 114, 116, 117 and119, memory module 115, and voltage regulator are powered off andprocessor 105 is placed in sleep mode. In certain embodiments, currentconsumption of this deep-sleep mode may be between 1 uA and 200 uA. Insleep mode, processor 105 does not function, except to receive a“wake-up” signal. The wake-up signal may, in some embodiments, bereceived through wireless communications module 122. In someembodiments, integrated data recorder 100, 200 may be placed in deepsleep mode by a software command to processor 105 received throughwireless communications module 122. Integrated data recorder 100, 200may be transitioned from deep-sleep mode to standby mode bycommunicating the wake-up signal to processor 105 through wirelesscommunications module 122 while processor 105 is in passive mode. Insome embodiments, processor 105 may be woken up by one or more activemode predetermined event criteria including, for example and withoutlimitation, an inclination trigger, RPM trigger, temperature trigger,vibration trigger, or pressure trigger, in which a certain inclinationof tool 300, rotation rate of tool 300, temperature measurement,vibration of tool 300, or pressure measurement, respectively, measuredby one or more corresponding sensors of sensor package 110 of integrateddata recorder 100, 200 causes processor 105 to enter the standby oroperational state.

Deep-sleep mode may, for example and without limitation, extension ofbattery life during transportation and/or storage without requiringphysical disassembly of integrated data recorder 100, 200. Physicaldisassembly of integrated data recorder 100, 200 may damage seals,threads, wires, and other elements if done by an unfamiliar technicianin a remote location. The recorder may be in “deep-sleep mode” for asmuch as between 1 month and 1 year before it is sent downhole fordynamics data logging.

In standby mode, processor 105 and at least one sensor (active sensor)of sensor package 110 are active. Digital solid-state sensors may be putinto standby mode using a digital command. Standby current to remainingsensors of sensor package 110 may be around 1 μA to 200 uA. Once anactive mode predetermined event criterion is met, as determined, forexample, by the active sensor, processor 105 sends a command to theremaining sensors of sensor package 110 to begin measurement of data andto memory module 115 to begin logging data (“active mode”).

FIG. 14 is a block diagram of an embodiment of integrated data recorder100, 200. Integrated data recorder 100, 200 may include sensor package110 having a plurality of sensors.

The active mode predetermined event criterion may be, for example, atemperature, acceleration, acceleration standard deviation, rotationspeed standard deviation, or inclination threshold as determined by theactive sensor. The active mode predetermined event may also be a drillstring or bit rotation rate threshold. In some embodiments, the activemode predetermined event criterion may be a combination of one or moreof a temperature threshold, acceleration threshold, accelerationstandard deviation threshold, rotation speed standard deviationthreshold, inclination threshold, drill string rotation rate threshold,or bit rotation rate threshold. In some embodiments, the active modethreshold that predetermines event criterion may be stored in digital,solid-state sensors, which may generate interrupt events to processor105. For example, one non-limiting example of a digital, solid-statesensor with such feature is an I²C digital temperature sensor, ModelMCP9800 from Microchip (Chandler, Ariz., USA). Temperature thresholdswith hysteresis (e.g. upper threshold and lower threshold) may be storedin MCP9800. In certain embodiments, all sensors are non-active duringstandby mode and the drill string or bit rotation (using accelerometers,gyros, magnetometers or a combination thereof) may be communicated toand received by integrated data recorder 100, 200 via downlinkcommunication from the surface. In certain embodiments, downlinkcommunication may be accomplished by mud-pulse telemetry,electro-magnetic (EM) telemetry, wired-drill-pipe telemetry or acombination thereof. In other embodiments, downlink communication may beaccomplished by varying the drill string rotation rate, for example andnot limited to the method described in US Patent Publication No.2017/0254190, entitled System and Method for Downlink Communication,published Sep. 7, 2017.

In certain embodiments, during active mode, once a predetermined passivemode criterion has been met, processor 105 may send a command to thesensors of sensor package 110 and memory module 115 to return to standbymode, thereby discontinuing measurement of data by the sensors andlogging of data by memory module 115. The passive mode predeterminedevent criterion may be, for example, a temperature threshold,acceleration threshold, acceleration standard deviation threshold, RPMthreshold, or inclination threshold as determined by one or more sensorsof sensor package 110. In some embodiments, the passive mode thresholdsthat predetermine event criterion may be stored in digital, solid-statesensors, which may generate interrupt events to processor 105. Onenon-limiting example of digital, solid-state sensor with such feature isan I²C digital temperature sensor, Model MCP9800 from Microchip(Chandler, Ariz., USA). Temperature thresholds with hysteresis (e.g.upper threshold and lower threshold) may be stored in MCP9800. In onenon-limiting example, the digital, solid state sensor made may changefrom the passive mode (no logging) to the active mode (logging) and fromthe active mode (logging) to the passive mode (no logging) multipletimes, based on one or more, or a combination of event thresholds.

In active mode, sensors in sensor package 110 are turned on for apredetermined duration at a predetermined log interval for measurementof drilling dynamics data. Examples of predetermined duration include1-10 seconds. Examples of predetermined log intervals are every 1, 2, 5,10, 20, 30, or 60 seconds and durations between those values.Predetermined log intervals for each of the sensors in sensor package110 may be the same or different. Predetermined durations for each ofthe sensors in sensor package 110 may be the same or different.

In certain embodiments, the sensors of sensor package 110 record burstdata to memory module 115 at a burst data frequency. In someembodiments, the burst data frequency may, for example and withoutlimitation, be 20 Hz or more, 50 Hz or more, 100 Hz or more, 200 Hz ormore, 400 Hz or more, 800 Hz or more, 1600 Hz or more, or 3200 Hz ormore. Examples of burst data log interval include every 1, 2, 5, 10, 20,30, or 60 seconds. The sensor burst data may be buffered in digitalsensors in the built-in sensor memory, which may be configured as FIFO(first-in first-out) memory. In certain embodiments, processor 105 doesnot store sensor burst data in processor's RAM (random access memory),i.e., sensor data is sent directly from the sensors in sensor package110 to memory module 115. In certain embodiments, processor 105 maystore a predetermined number of samples of sensor burst data (forexample, just one sample of sensor burst data) in the RAM of processor105 prior to sending the sensor burst data to memory module 115. Inother embodiments, high-frequency sampling data, for example, at 3200Hz, is continuously stored to memory module 115, such as continuouslybursting and recording.

The use of the FIFO memory of a sensor may reduce processor 105processing capability requirements and processor 105 power consumption.In certain embodiments, the number of the FIFO memories of a sensor maybe between 32 and 1025 data points, or between 32 and 512 data pointsper sensor axis. One FIFO memory may hold, for example, 16 bits or 32bits, depending on the sensor output resolution. For example, a 3-axissensor may contain up to 16-bit×100-points×3-axis=48000 bits of FIFOmemory. In some embodiments, the sensors of sensor package 110 mayrecord statistics of some or each of the sensors. For example, thestatistics of the high-g 3-axis accelerometer data, such as minimum,maximum, mean, median, root-mean-squared, standard deviation, andvariance values may be recorded by the sensor package and, in certainembodiments, transmitted to memory module 115. In some embodiments,sensor package 110 may record burst data of the low-g 3-axis digitalaccelerometer data and 3-axis digital gyroscope. In other embodiments,sensor package 110 may record continuously sampled data, for example, at1600 Hz, of the 3-axis digital accelerometer data and 3-axis digitalgyroscope. Raw analog-to-digital counts for accelerometers andgyroscopes, i.e., a number representing voltage, may be recorded inmemory module 115 without temperature calibration or conversion to finalunits. In certain embodiments, temperature calibration may be performedby processor 105 for drilling dynamics data measured by the sensors ofsensor package 110. Temperature calibration may correct for the scaledrift factor and offset drift over temperature. In certain embodiments,temperature calibration may be accomplished, for example, by look-uptables.

In some embodiments, ranges of some or all of the sensors in sensorpackage 110 may be changed while integrated data recorder 100, 200 iswithin the wellbore. For example, the low-G accelerometer sensing rangeis programmable and changeable downhole from +/−4G to +/−16G and allranges therebetween. Ranges may be changed based on attainment of apredetermined range threshold value or by communication by downlink fromthe surface. Examples of predetermined range thresholds include, but arenot limited to values of rotation speed standard deviation, accelerationstandard deviation, or combinations thereof.

In certain embodiments, sampling frequency of some or all of the sensorsin sensor package 110 may be changed while integrated data recorder 100,200 is within the wellbore. Sample frequency may be changed based onattainment of a predetermined sampling threshold value or bycommunication by downlink from the surface. Examples of predeterminedsampling thresholds include, but are not limited to, values of rotationspeed standard deviation, acceleration standard deviation, orcombinations thereof.

In some embodiments, some or all of the sensors in sensor package 110may include an anti-aliasing filter on one or all of the axes of thesensor. The frequency of the anti-aliasing filter may be changed whileintegrated data recorder 100, 200 is within the wellbore. For example,the anti-aliasing filter may be changed to between 25 Hz and 3200 Hz foraccelerometers. In some embodiments, the anti-aliasing filter frequencymay be changed when sampling frequency is changed to avoid aliasing.

In some embodiments, integrated data recorder 100, 200 may with an MWDtool through communications port 120 or through wireless communicationsmodule 122. In one non-limiting example, statistics of downhole dynamicsdata (for example, maximum shock, RPM standard deviation,root-mean-squared shock, mean vibration, median inclination, etc.) maybe transmitted to surface via an MWD mud-pulse telemetry,electro-magnetic (EM) telemetry, EM short-hop telemetry,wired-drill-pipe telemetry or a combination thereof. In someembodiments, the sensor data may be transmitted to the MWD toolwirelessly. For example, an at-bit integrated data recorder 100, 200 maytransfer the sensor data from the bit to an MWD tool with a wirelessmodule, via integrated data recorders 100, 200 placed at multiplelocations in a bottom-hole assembly (BHA). A wireless network, such as,for example and without limitation, Z-wave, may allow the datatransferred from one device to another via other wireless modules usingZ-wave's source-routed mesh network architecture. In some embodiments,the MWD tool may relay the drilling dynamics data to surface via acommunications channel including, for example and without limitation,mud-pulse telemetry, electro-magnetic (EM) telemetry, EM short-hoptelemetry, wired-drill-pipe telemetry or a combination thereof. In someembodiments, wireless integrated data recorders placed at many differentpositions in a drill string may relay at-bit sensor information from abit to surface, such as, for example, for real-time geo-steeringapplications.

In some embodiments, integrated data recorder 100, 200 may be positionedin an existing tool. In some embodiments, integrated data recorder 100,200 may be added to the downhole tool without altering the tool lengthor mechanical integrity of the tool. In some such embodiments, a slot asdescribed herein above may be formed in one or more components of theexisting tool, and one or more integrated data recorders 100, 200 may beplaced therein.

In some embodiments, integrated data recorder 100, 200 may be utilizedduring transportation of tool 300. In such an embodiment, integrateddata recorder 100, 200 may measure one or more aspects of the movementof tool 300 including, for example and without limitation, the locationof tool 300 and one or more parameters relating to the handling of tool300 including detection of drops, shock loads, or other mishandling oftool 300.

In some embodiments, information about the operation of bottom-holeassembly (BHA) may be transmitted to the surface via mud pulsetelemetry. In some embodiments, temperature difference, temperaturegradient, and other drilling dynamics information may be classified intodifferent severity levels, for example, 4 to 8 severity levelsindicative of a measured condition. As a non-limiting example, inembodiments in which 2-bit severity levels (4 levels) are used, atemperature difference may be coded as Level 1 which may be between 0and 2 degrees centigrade, Level 2 between 2 and 4 degrees centigrade,Level 3 between 4 and 6 degrees centigrade, and Level 4 above 6 degreescentigrade. Similarly, downhole acceleration events or shocks may becoded as Level 1 (no shock) between 0 and 10 g, Level 2 (low) between 10and 40 g, Level 3 (medium) between 40 and 100 g, and Level 4 (high)above 100 g. As another example, high-frequency torsional oscillation(HFTO) may be detected with tangential acceleration measurement orangular gyro measurement with an expected frequency range, for example,between 100 and 1600 Hz. Angular acceleration can be calculated bytime-differentiating the angular gyro velocity. By applying a digitalband-pass, digital band-reject, analog band-pass, analog band-reject,high-pass filter, digital high-pass filter, analog high-pass filter, ora combination thereof on a tangential accelerometer or gyro, downholeHFTO events may be coded as Level 1 (no HFTO) between 0 and 10 g, Level2 (low HFTO) between 10 and 40 g, Level 3 (medium HFTO) between 40 and100 g, and Level 4 (high HFTO) above 100 g. Alternatively, at integrateddata recorder, filtered accelerations (for example, tangentialaccelerations, lateral accelerations, radial accelerations, angularaccelerations, axial accelerations, etc.) may be used to estimatepseudo-formation-evaluation parameters, such as pseudo-sonic log,pseudo-neutron log, pseudo-porosity log, pseudo-density log, andpseudo-Gamma log. Pseudo formation-evaluation parameters and/or theirseverity levels may be transmitted to surface for geo-steering.

Rock mechanics parameters (e.g. Young's modulus, Poisson's ratio,compressive strength, and Fractures) may be detected with tri-axialhigh-frequency acceleration measurement with an expected frequencyrange, for example, between 100 and 1000 Hz, as described, for examplein SPWLA 2017—“A Novel Technique for Measuring (Not Calculating) Young'sModulus, Poisson's Ratio and Fractures Downhole: A Bakken Case Study”.By applying a digital band-pass, digital band-reject, analog band-pass,analog band-reject, digital high-pass filters, analog high-pass filters,or a combination thereof on the at least one accelerometer or gyro,downhole fractures may be coded as Level 1 (no fractures) between 0 and10, Level 2 (low) between 10 and 40, Level 3 (medium) between 40 and100, and Level 4 (high) above 100 (the numbers are without units, butcorrelated to the number of fractures). Rock mechanics parameters and/ortheir severity levels may be transmitted to surface for geo-steering.

The foregoing outlines features of several embodiments so that a personof ordinary skill in the art may better understand the aspects of thepresent disclosure. Such features may be replaced by any one of numerousequivalent alternatives, only some of which are disclosed herein. One ofordinary skill in the art should appreciate that they may readily usethe present disclosure as a basis for designing or modifying otherprocesses and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein. Oneof ordinary skill in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

The invention claimed is:
 1. A method comprising: providing a firstintegrated data recorder, the first integrated data recorder positionedwithin a tool, the tool being a steering tool of a bottomhole assembly,the first integrated data recorder including: a sensor package, thesensor package comprising one or more drilling dynamics sensors; amemory module, the memory module in data communication with the sensorpackage; a wireless communications module, the wireless communicationsmodule in data communication with the processor; a processor, theprocessor in data communication with the one or more drilling dynamicssensors; and an electrical energy source, the electrical energy sourcein electrical communication with the memory module, the sensor package,and the processor; taking measurements using the drilling dynamicssensors, the measurements comprising pseudo formation-evaluationparameters; transmitting the measurements from the drilling dynamicssensors to an external device using the wireless communications module;and geo-steering the bottomhole assembly based on the pseudoformation-evaluation parameters.
 2. The method of claim 1, furthercomprising memory logging the measurements from the drilling dynamicssensors in the memory module: removing the tool from the wellbore; andretrieving the drilling dynamics data with a surface processor.
 3. Themethod of claim 2, further comprising using the drilling dynamics datafor post run analysis, real-time analysis, or a combination thereof ofrock mechanics.
 4. The method of claim 2, further comprising using thedrilling dynamics data for post run evaluation of drilling dynamics,frequency spectrum, statistical analysis, condition-basedmonitoring/maintenance (CBM), or a combination thereof.
 5. The method ofclaim 4, further comprising prior to positioning the tool within thewellbore, operating the first integrated data recorder in deep-sleepmode.
 6. The method of claim 5, further comprising: sending a wake-upsignal to the first integrated data recorder; and operating the firstintegrated data recorder in standby mode.
 7. The method of claim 6,further comprising: receiving a downlink communication, the downlinkcommunication including one or more of drill string or bit rotation;operating the first integrated data recorder in active mode when theprocessor receives the downlink communication.
 8. The method of claim 7,wherein the taking measurements using the drilling dynamics sensors stepis performed for a predetermined duration at a predetermined loginterval.
 9. The method of claim 8, wherein the predetermined durationis between 1 and 10 seconds.
 10. The method of claim 8, wherein thepredetermined log interval is between 1 and 60 seconds.
 11. The methodof claim 8, wherein continuously sampled data is recorded in memory. 12.The method of claim 6, wherein the plurality of drilling dynamicssensors includes an active sensor and one or more remaining sensors, themethod further comprising: setting an active mode predetermined eventcriterion; measuring drilling dynamics data using the active sensor; andoperating the first integrated data recorder in active mode when theactive sensor in combination with the processor determines that theactive mode predetermined event criterion has occurred.
 13. The methodof claim 12, wherein the active mode predetermined event criterioncomprises a temperature threshold, acceleration threshold, accelerationstandard deviation threshold, rotation speed standard deviationthreshold, inclination threshold, drill string rotation rate threshold,bit rotation rate threshold, or a combination thereof.
 14. The method ofclaim 13, wherein the temperature threshold, acceleration threshold,acceleration standard deviation threshold, rotation speed standarddeviation threshold, inclination threshold, drill string rotation ratethreshold, or bit rotation rate threshold is stored in the activesensor, the active sensor configured to generate an interrupt event tothe processor when the active mode predetermined event criterion hasoccurred.
 15. The method of claim 1, wherein the drilling dynamicssensors burst data to the memory module at a burst data frequency. 16.The method of claim 15, wherein the burst data is logged at a loginterval, wherein the log interval is between 1 and 60 seconds.
 17. Themethod of claim 16, wherein the sensors include memory and wherein theburst data is stored in the sensor's memory.
 18. The method of claim 16,wherein the sensors include sensor memory, and wherein continuouslysampled data is stored in sensory memory.
 19. The method of claim 1,wherein the drilling dynamics data is calibrated for temperature. 20.The method of claim 1, wherein the drilling dynamics sensors have rangesand wherein the ranges are changed while the tool is within thewellbore.
 21. The method of claim 1, wherein the drilling dynamicssensors have a sampling frequency and wherein the sample frequency ischanged while the tool is within the wellbore.
 22. The method of claim1, wherein the drilling dynamics sensors include an anti-aliasing filterand the anti-aliasing filter is changed while the tool is within thewellbore.
 23. The method of claim 1, further comprising communicatingwith a measurement-while drilling (MWD) through a communications port indata communication with the memory module.
 24. The method of claim 1,further comprising communicating with a measurement-while drilling (MWD)wirelessly through the wireless communications module in datacommunication with the memory module.
 25. The method of claim 1, furthercomprising memory logging the measurements from the one or more drillingdynamics sensors in the memory module to form drilling dynamics data.26. The method of claim 1, wherein the measurements from the drillingdynamics sensors are transmitted continuously.
 27. The method of claim1, further comprising processing the measurements to formdownhole-processed pseudo-formation-evaluation data; and transmittingthe downhole-processed pseudo-formation-evaluation data continuously.28. The method of claim 1, further comprising: positioning the toolwithin a wellbore, wherein the measurements are taken using the drillingdynamics sensors while the tool is within the wellbore; memory loggingthe measurements from the one or more drilling dynamics sensors in thememory module to form drilling dynamics data; and retrieving the toolfrom the wellbore to the surface, wherein transmitting the measurementscomprises transmitting the memory logged measurements from the memorymodule.
 29. The method of claim 1, wherein the measurements furthercomprise geomechanics parameters, and wherein the method furthercomprises geo-steering the bottomhole assembly based on the geomechanicsparameters.
 30. The method of claim 1, wherein the pseudo-formationevaluation parameters comprise one or more of pseudo-sonic log,pseudo-neutron log, pseudo-porosity log, pseudo-density log, andpseudo-Gamma log.
 31. The method of claim 1, further comprisingtransmitting the measurements from the drilling dynamics sensors to thecloud with the external device.
 32. The method of claim 1, furthercomprising: providing a second integrated data recorder; andtransmitting the measurements from the drilling dynamics sensors fromthe second integrated data recorder to the first integrated datarecorder.
 33. The method of claim 32, wherein one of the first or secondintegrated data recorders is positioned in a wellbore, and the other ofthe first or second integrated data recorders is positioned at thesurface.
 34. The method of claim 33, wherein the surface integrated datarecorder is positioned in a kelly, a saver sub, a quill, or a tool jointclamp of a top drive located at the surface.
 35. A method comprising:providing a first integrated data recorder, the first integrated datarecorder positioned within a tool, the first integrated data recorderincluding: a sensor package, the sensor package comprising one or moredrilling dynamics sensors; a memory module, the memory module in datacommunication with the sensor package; a wireless communications module,the wireless communications module in data communication with theprocessor; a processor, the processor in data communication with the oneor more drilling dynamics sensors; and an electrical energy source, theelectrical energy source in electrical communication with the memorymodule, the sensor package, and the processor; taking measurements usingthe drilling dynamics sensors; transmitting the measurements from thedrilling dynamics sensors to an external device using the wirelesscommunications module; providing a second integrated data recorder;operating the first and second integrated data recorders to record thesame data at the same or higher resolution; and transmitting themeasurements from the drilling dynamics sensors from the secondintegrated data recorder to the first integrated data recorder.
 36. Themethod of claim 35, comprising comparing downhole drilling dynamics datarecorded by the first integrated data recorder and surface drillingdynamics data from the second integrated data recorder by a surfaceprocessor of the external device.
 37. The method of claim 36, furthercomprising identifying one or more operational anomalies from thecompared downhole and surface drilling dynamics data.
 38. The method ofclaim 36, further identifying detecting downhole disfunctions from thecompared downhole and surface drilling dynamics data.
 39. The method ofclaim 36, further comprising correlating the downhole and surfacedrilling dynamics data to identify a correlation between bit and/ordrillstring drilling dynamics data and surface dynamics data.
 40. Themethod of claim 39, further comprising identifying one or more downholeproblems or operational anomalies using surface drilling dynamics data.41. The method of claim 40, wherein surface drilling dynamics data aretransmitted wirelessly to the surface processor in real-time.
 42. Themethod of claim 36, wherein the first integrated data recorder and thesecond integrated data recorder are identical.
 43. A method comprising:providing a first integrated data recorder, the first integrated datarecorder positioned within a tool, the first integrated data recorderincluding: a sensor package, the sensor package comprising one or moredrilling dynamics sensors; a memory module, the memory module in datacommunication with the sensor package; a wireless communications module,the wireless communications module in data communication with theprocessor; a processor, the processor in data communication with the oneor more drilling dynamics sensors; and an electrical energy source, theelectrical energy source in electrical communication with the memorymodule, the sensor package, and the processor; taking measurements usingthe drilling dynamics sensors; transmitting the measurements from thedrilling dynamics sensors to an external device using the wirelesscommunications module; providing a second integrated data recorder;transmitting the measurements from the drilling dynamics sensors fromthe second integrated data recorder to the first integrated datarecorder; and running one or more pattern recognition algorithms on themeasurements from the first and second integrated data recorders toidentify operational or data anomalies.
 44. The method of claim 43,wherein the pattern recognition algorithm comprises artificialintelligence or machine learning.
 45. The method of claim 43, furthercomprising identifying an anomaly, and adjusting one or more surfaceparameters until a different or smoother signal is received.